Apparatus and method for thawing a product

ABSTRACT

A method and apparatus for thawing a commodity includes a plurality of boxes arranged in two rows with a cover for sealing the space between the two rows. A plenum is formed between the two rows of boxes with the plurality of boxes being positioned side-by-side. At least one air handler is provided for pulling air within a predetermined temperature range through ventilation holes in the boxes and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. In addition, the air may be forced along the length of the space formed between the two rows of boxes and through ventilation holes in the boxes and/or through spacers positioned underneath adjacent boxes for evenly thawing a commodity positioned in the boxes.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser. No. 11/336,900, filed on Jan. 23, 2006, which claimed priority to U.S. Provisional Patent Application No. 60/645,027, filed on Jan. 21, 2005, the entire contents of which are incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to an apparatus and method for thawing a frozen commodity such as a food product.

2. Description of Background Art

A problem occurs in the food industry when it is desired to thaw a food product. For example, the food products may be positioned on a loading dock and subjected to ambient air to thaw the food products. Normally, a plurality of pallets of food products are arranged on the loading dock or in a warehouse and ambient air is blown or pushed towards the pallets. If the ambient air is at 72° Fahrenheit (22.22° Celsius), the first pallet of food products will thaw first and may reach a temperature above the mandated safety zone of 40° Fahrenheit (4.44° Celsius). The thawing of the food products on a loading docket or in a warehouse may lead to the growth of bacteria in the food products that may be transmitted to contaminate adjacent food products and other areas of the warehouse. In addition, the thawing of a food product in this manner may lead to the discoloration of the food product. Further, the food products will be thawed unevenly and thus lead to problems in determining which food products are properly thawed for delivery to a customer. Still further, the thawing of frozen food products in ambient air leads to the production of condensation within the boxes of the food products. This will produce a wet or soggy box with a wet food product that is not suitable for delivery to a customer.

Another way to thaw a food product is to position the food product in a cooler that is maintained at a temperature of approximately 37° Fahrenheit to 70° Fahrenheit (2.77° Celsius to 21.11° Celsius). Again the pallets of food products have air that is blown or pushed towards the pallets. The pushing of the air unto the pallets of food products will lead to the thawing of the food on the pallet that is located immediately adjacent to the air handler. Pallets of food products that are displaced away from the first pallet will be thawed at a different rate. It is difficult to determine when the various pallets of food products are properly thawed. Uneven thawing will lead to the need to use a longer time to thaw the food products. By using the conventional blowing or pushing of air method towards the food products, it takes approximately 7 to 10 days to thaw a frozen food product, such as ham or turkey, in a cooler.

SUMMARY AND OBJECTS OF THE INVENTION

It is an object of the present invention to provide a method and apparatus for thawing a commodity by pulling air through and/or around pallets and through ventilation holes in boxes stacked on the pallets.

It is another object of the present invention to provide a method and apparatus for thawing a commodity, such as thawing a food product, by pulling air through and/or around pallets and through the ventilation holes in the boxes stacked on the pallets.

It is a further object of the present invention to provide a plurality of pallets of the commodity that are formed in two rows with a space formed therebetween. A cover is positioned over the space to form a plenum. An air handler is positioned to pull air from between the plurality of pallets and through the ventilation holes in the boxes stacked on the pallets and along the length of the space formed between the two rows for achieving an even flow of air for thawing the commodity positioned on the pallets.

These and other objects of the present invention are achieved by providing an apparatus for thawing a commodity that includes a plurality of boxes of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. A plenum is formed between the two rows of boxes to permit a flow of air through ventilation holes in the boxes. At least one air handler is provided for pulling air within a predetermined temperature range through the ventilation holes in the boxes and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. An even flow of air is pulled through the ventilation holes in the boxes and along the length of the space formed between the two rows of boxes to evenly thaw a commodity positioned in the boxes. Corrugated material may be positioned between adjacent boxes to provide a ventilation space therebetween.

These and other objects of the present invention are achieved by providing an apparatus to thaw a commodity including a first box of a commodity and a second box of a commodity. The first and second boxes are disposed adjacent to each other with a space formed therebetween. A plenum is formed between the first box and said second box to permit a flow of air through the boxes. At least one air handler is provided for pulling air within a predetermined temperature range through the boxes and along a length of the space formed between the first and second boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. An even flow of air is evenly pulled through the first box and the second box and along the length of the space formed between the first and second boxes to evenly thaw a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing an apparatus to thaw a commodity including a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. Ventilation spacers are positioned underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween. A plenum is formed between the two rows of pallets wherein a flow of air is pulled through the ventilation spacers disposed between the boxes on the pallets. At least one air handler is provided for pulling air within a predetermined temperature range through the ventilation spacers in the boxes and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. An even flow of air is evenly pull air through the ventilation spacers and along the length of the space formed between the two rows of pallets to evenly thaw a commodity positioned in the boxes on the pallets.

These and other objects of the present invention are achieved by providing a method to thaw a commodity comprising the steps of positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween. Forming a plenum between the two rows of boxes to permit a flow of air through ventilation holes in the boxes. Pulling air within a predetermined temperature range through the ventilation holes in the boxes and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Providing an even flow of air to evenly pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows of boxes to evenly thaw a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing a method to thaw a commodity comprising the steps of providing a first box and second box of a commodity disposed adjacent to each other with a space formed therebetween. Forming a plenum between the first box and the second box to permit a flow of air through the boxes. Pulling air within a predetermined temperature range through the boxes and along a length of the space formed between the first and second boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Providing an even flow of air to evenly pull air through the first box and the second box and along the length of the space formed between first and second boxes to evenly thaw a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing a method to thaw a commodity comprising the steps of providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. Providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween. Forming a plenum between said two rows of pallets wherein a flow of air is pulled through the ventilation spacers disposed underneath the boxes on the pallets. Pulling air within a predetermined temperature range through the ventilation spacers and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Providing an even flow of air to evenly pull air through the ventilation spacers and along the length of the space formed between the two rows of pallets to evenly thaw a commodity positioned in the boxes on the pallets.

These and other objects of the present invention are achieved by providing an apparatus to thaw a commodity including a plurality of boxes of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. A plenum is formed between the two rows of boxes to permit a flow of air through ventilation holes in the boxes. At least one air handler is provided for forcing air within a predetermined temperature range through the air handler, along a length of the space formed between the two rows and through the ventilation holes in the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time wherein an even flow of air is forced through the air handler, along the length of the space formed between the two rows of boxes and through the ventilation holes in the boxes to evenly thaw a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing an apparatus to thaw a commodity includes a first and second box of a commodity being disposed adjacent to each other with a space formed therebetween. A plenum is provided between the first box and said second box to permit a flow of air through the boxes. At least one air handler is provided for forcing air within a predetermined temperature range through the air handler, along a length of the space formed between the first and second boxes and through the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time, wherein an even flow of air is evenly forced through the at least one air handler, along the length of the space and through the first box and the second box to evenly thaw a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing an apparatus to thaw a commodity includes a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. Ventilation spacers are positioned underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween. A plenum is provided between the two rows of pallets wherein a flow of air is forced through the ventilation spacers disposed between the boxes on the pallets. At least one air handler forcing air within a predetermined temperature range through the air handler, along a length of the space formed between the two rows through the ventilation spacers disposed underneath the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time, wherein an even flow of air is evenly forced through the air handler, along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly thaw a commodity positioned in the boxes on the pallets.

These and other objects of the present invention are achieved by providing a method to thaw a commodity includes positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween. Forming a plenum between the two rows of boxes to permit a flow of air through ventilation holes in the boxes. Forcing air within a predetermined temperature range along a length of the space formed between the two rows, through the ventilation holes in the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Providing an even flow of air to evenly force air along the length of the space formed between the two rows of boxes and through the ventilation holes in the boxes to evenly thaw a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing a method to thaw a commodity includes providing a first and second box of a commodity being disposed adjacent to each other with a space formed therebetween. Forming a plenum between the first box and the second box to permit a flow of air through the boxes. Forcing air within a predetermined temperature range along a length of the space formed between the first and second boxes and through the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Providing an even flow of air to evenly force air through length of the space formed between the two rows and through the first box and the second box to evenly thaw a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing a method to thaw a commodity includes providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. Providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween. Forming a plenum between the two rows of pallets wherein a flow of air is forced through the ventilation spacers disposed underneath the boxes on the pallets. Forcing air within a predetermined temperature range along a length of the space formed between the two rows, through the ventilation spacers and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Providing an even flow of air to evenly force air along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly thaw a commodity positioned in the boxes on the pallets.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:

FIG. 1 is a side elevational view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets;

FIG. 2 is a top plan view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets;

FIG. 3 is a end view of the pallets with a commodity stacked thereon;

FIG. 4 is a end elevational view of an air handler that is positioned between the two rows of pallets;

FIG. 5 is a side elevational view of the air handler illustrated in FIG. 4;

FIG. 6 is a top plan view of the air handler illustrated in FIG. 4;

FIG. 7 is a side elevational view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets and with the spaces formed between adjacent pallets being covered;

FIG. 8 is a top plan view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets and the spaces formed between adjacent pallets being covered;

FIG. 9 is an end view illustrating a plurality of boxes that are arranged in rows and stacked with corrugated material being disposed underneath and between adjacent boxes for permitting ventilation by pulling air underneath and between adjacent boxes;

FIG. 10 is a side view illustrating a plurality of boxes that are stacked on each other with corrugated material being disposed underneath and between adjacent boxes for permitting ventilation by pulling air underneath and between adjacent boxes.

FIG. 11 is end view illustrating a plurality of boxes that are arranged in rows and stacked with plastic formed spacer being disposed underneath adjacent boxes for permitting ventilation by pulling air underneath adjacent boxes;

FIG. 12 is an end view illustrating a plurality of boxes that are stacked on each other with wood slat spacers being disposed underneath adjacent boxes for permitting ventilation by pulling air underneath adjacent boxes;

FIG. 13 is a top plan view of a plurality of pallets of a commodity being spaced relative to each other according to a second embodiment with air handlers being directly disposed to be in communication with the plenum; and

FIG. 14 is a side elevational view of a plurality of pallets of a commodity being spaced relative to each other according to the second embodiment wherein the air handlers are directly disposed to be in communication with the plenum.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIGS. 1-3, an apparatus 10 is provided for thawing a commodity, such as thawing a food product. A plurality of pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D are provided with the commodity stacked on the pallets and the pallets arranged in two rows I and II with a space S formed therebetween. The term space means that the pallets are substantially equally disposed relative to each other to form a continuous space between the pallets. In addition, the term space means that the pallets may be arranged at an angle with corners of the end pallets engaging each other and the space continuing to enlarge from the end pallets to an air handler 20.

A cover C is positioned to be placed on the space S to seal the two rows of pallets along the top space S. In addition, the cover C may be positioned on at least on a portion of the top surface 12 of the commodities for sealing the two rows of pallets along the top surface to form the plenum. In addition, the cover C may also extend along end surfaces 14, 16 for sealing the space S between the two rows of pallets to form the plenum. In another embodiment, the cover C may extend along at least a portion of the top surface 12 and the end surfaces 14, 16 to seal the space S and to form the plenum. The cover C may be a flexible tarp for positioning on the top surface of the commodities that is sucked up tight to make a seal as air is pulled through the space S formed between the pallets and through the ventilation holes H in the boxes stacked on the pallets. In another embodiment, the cover C may be a more rigid board material that is positioned on the space S or on at least a portion of the top surface of the commodities.

As stated above, it is to be understood that the two rows I and II of pallets 1A-5A, 1B-5B and 1C-5C, 1D-5D may be arranged in straight rows as illustrated in FIGS. 1 and 2. In another embodiment, the two rows I and II may be formed at an angle wherein the end pallets of boxes 1A, 1B and 5C, 5D touch each other for closing the rows. This embodiment is contemplated by the claims and is equivalent to positioning the cover C over the ends of the two rows I and II of pallets for sealing the ends.

A plenum P is formed between the two rows I and II of the pallets 1A-5A, 1B-5B and 1C-5C, 1D-5D with the plurality of pallets being spaced apart 11A-14A, 11B-14B, 11C-14C and 11D-14D from adjacent pallets to permit a flow of air therebetween. The boxes of commodities positioned on the pallets include a plurality of ventilation holes H for permitting air to be pulled through the boxes as the commodity is thawed.

The air handler 20 is positioned between the two rows I and II of pallets and is spaced along a length thereof. As illustrated in FIGS. 1 and 2, the air handler 20 is disposed at approximately the mid-point of the two rows I and II. In other embodiments of the present invention, two or more air handlers 20 may be positioned along the length of the two rows I and II to ensure a proper flow of air between the pallets. The air handler 20 pulls air from between the plurality of pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along a length of the space S formed between the two rows I and II and discharges the air either upwardly, horizontally or downwardly therefrom. The discharge of air upwardly permits the air that has been cooled by thawing a commodity to be discharged towards the ceiling in the room in which the pallets are positioned.

As illustrated in FIGS. 4-6, the air handler 20 includes a housing 22, 24 that is approximately the size of a pallet loaded with boxes of a commodity. At least one fan 26 that is operatively connected to a motor is disposed within the housing for creating an even flow of air that is pulled from between adjacent pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along the two rows I and II of the pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D and through the holes H in the boxes for evenly thawing a commodity positioned in the boxes on the pallets.

As illustrated in FIGS. 5 and 6, two fans 26, 28 may be provided for creating an even flow of air that is pulled between adjacent pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along the two rows I and II of the pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D and through the ventilation holes H in the boxes for evenly thawing a commodity positioned in the boxes on the pallets.

By positioning the air handler 20 between the rows I and II of pallets, an even flow of air is achieved from between adjacent pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along the two rows I and II of the pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D and through the holes H in the boxes for evenly thawing a commodity positioned in the boxes on the pallets.

As illustrated in FIGS. 1, 4 and 5, the cover C or tarps 32, 34 may be secured directly on the air handler 20 for permitting the cover C or tarps 32, 34 to be extended therefrom for covering the space S or at least a portion of the top surface 12 of the commodities positioned in the boxes disposed on the pallets. The cover C or tarps 32, 34 may be rolled up for storage by using the handles 33, 35. In one embodiment, the cover C or tarps 32, 34 may also extend along end surfaces 14, 16 for sealing the space S between the two rows of pallets along the top surface 12 and the end surfaces 14, 16.

In one embodiment of the present invention, the pallets are positioned in a cooler wherein the temperature of the cooler is maintained at approximately 37° Fahrenheit to 70° Fahrenheit (2.77° Celsius to 21.11° Celsius). The commodity may be raised to a temperature above the mandated safe zone of 40° Fahrenheit (4.44° Celsius) for no more than four (4) hours and thereafter should be lowered to be below the mandated safe zone of 40° Fahrenheit (4.44° Celsius). At least one air handler is provided for pulling air within a predetermined temperature range through the ventilation holes in the boxes and along a length of the space S formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. To thaw a frozen food product it is necessary to remove the latent heat of the frozen product to be in a state where the frozen food product is thawed. Removing latent heat requires additional BTUs as compared to cooling a product from a warm temperature of 70° Fahrenheit to 85° Fahrenheit (21.11° Celsius to 29.44° Celsius) to a lower temperature of 60° Fahrenheit to 65° Fahrenheit (15.56° Celsius to 18.33° Celsius). According to the present invention, the thawing in a cooler occurs in approximately 24 to 36 hours. A substantial amount of energy can be conserved by using the cold air from the frozen product to maintain the temperature in the cooler at approximately 37° Fahrenheit to 70° Fahrenheit (2.77° Celsius to 21.11° Celsius). The cold, frozen product provides cooling for the cooler.

The present invention includes a method that may be used to thaw the commodity, such as a food product. The thawing of the commodity may be performed in a cooler that is maintained in a temperature range from 37 degrees F. to 70° Fahrenheit (2.77° Celsius to 21.11° Celsius) below the mandated safe zone of 40 degrees F. (4.44° Celsius) for thawing food products within the safe zone. At least one air handler is provided for pulling air within a predetermined temperature range through the ventilation holes H in the boxes and along a length of the space S formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time.

The present invention may be used with any number of pallets arranged in straight rows or in rows disposed at an angle relative to each other. The air handler 20 is portable for positioning the air handler 20 in a warehouse, a cooler, on a loading dock or in any environment for permitting the thawing of a commodity as the need arises. The present invention is not limited for use in a cooler. The present invention provides for tempered thawing for ensuring that a commodity is properly handled depending on the conditions required for the commodity.

The speed of thawing permits the present invention to process a commodity very quickly. For example, with regard to a food product, a code date is provided for the food product that starts to run as the food product is thawed. If the code date is 10 days, a conventional way of thawing the food product would take approximately 7 to 10 days. Thus, the code date has expired or almost expired by the time the food product is thawed. According to the present invention, the thawing occurs within 24 to 36 hours. Thus, a substantial time still remains with regard to the code date for permitting a customer to have sufficient time to use the food product in a restaurant or to sell the food product in a grocery store.

Pulling the air through the pallets makes it possible to form a plenum to block the air flow where needed by using a tarp that is sucked up tight to the space S to make a seal for forming a plenum or for the cover C to engage at least a portion of the top of the boxes to make a seal as compared to providing a rigid structure. By pulling the air through the pallets and through the ventilation holes H in the boxes stacked on the pallets the air flow seals the tarps to the space S or to the product without the need of using a rigid structure.

As illustrated in FIGS. 7 and 8, an apparatus 100 is provided for thawing a commodity, such as thawing a food product. A plurality of pallets 101A-105A, 101B-105B, 101C-105C and 101D-105D are provided with the commodity stacked on the pallets and the pallets arranged in two rows I and II with a space S formed therebetween. The term space means that the pallets are substantially equally disposed relative to each other to form a continuous space between the pallets. In addition, the term space means that the pallets may be arranged at an angle with corners of the end pallets engaging each other and the space continuing to enlarge from the end pallets to an air handler 20.

A cover C is positioned to be placed on the space S to form a plenum or may be positioned on at least on a portion of the top surface 112 of the commodities for sealing the two rows of pallets along the top surface. In one embodiment, the cover C can also extend along end surfaces 114, 116 for sealing the space S between the two rows of pallets along the space S or the cover C may extend along both the top surface 112 and the end surfaces 114, 116. The cover C may be a flexible tarp for positioning on the space S or on the top surface of the commodities that is sucked up tight to make a seal as an air flow is pulled through the ventilation holes H. In another embodiment, the cover C may be a more rigid board material that is positioned on the space S or on the top surface of the commodities.

As stated above, it is to be understood that the two rows I and II of pallets 101A-105A, 101B-105B and 101C-105C, 101D-105D may be arranged in straight rows as illustrated in FIGS. 7 and 8. In another embodiment, the two rows I and II may be formed at an angle wherein the end pallets of boxes 101A, 101B and 105C, 105D touch each other for closing the rows. This embodiment is contemplated by the claims and is equivalent to positioning the cover C over the ends of the two rows I and II of pallets for sealing the ends.

A plenum P is formed between the two rows I and II of the pallets 101A-105A, 101B-105B and 101C-105C, 101D-105D. The plurality of pallets may be spaced apart with covers 111A-114A, 111B-114B, 111C-114C and 111D-114D disposed in the space for blocking the flow of air. The covers 111A-114A, 111B-114B, 111C-114C and 111D-114D may be positioned on the exterior of the two rows I and II of the pallets as illustrated in FIGS. 7 and 8 for sealing the space formed between adjacent pallets. In addition, the covers 111A-114A, 111B-114B, 111C-114C and 111D-114D may be positioned on the interior of the two rows I and II of the pallets for sealing the space formed between adjacent pallets. The covers 111A-114A, 111B-114B, 111C-114C and 111D-114D may be a tarp that is secured to adjacent pallets with Velcro. The space between adjacent pallets may be eliminated if the boxes are stacked on the pallets with the boxes extending to the edge of the pallets so as to permit boxes stacked on adjacent pallets to touch each other. The boxes of commodities positioned on the pallets include a plurality of ventilation holes H for permitting air to be pulled through the boxes as the commodity is thawed.

The air handler 200 is positioned between the two rows I and II of pallets and is spaced along a length thereof. As illustrated in FIGS. 7 and 8, the air handler 200 is disposed at approximately the mid-point of the two rows I and II. In other embodiments of the present invention, two or more air handlers 200 may be positioned along the length of the two rows I and II to ensure a proper flow of air through the ventilation holes H in the boxes stacked on the pallets. The air handler 200 pulls air from through the ventilation holes H in the boxes stacked on the pallets and along a length of the space S formed between the two rows I and II and discharges the air either upwardly, horizontally or downwardly therefrom. The discharged air that has been cooled by thawing a commodity may be discharged towards the ceiling and/or horizontally and/or downwardly in the room in which the pallets are positioned.

FIGS. 9 and 10 illustrate another embodiment of the present invention wherein a plurality of boxes 200′ are arranged in rows and stacked with corrugated material 202 being disposed underneath the boxes 200′ and corrugated material 204 being disposed between adjacent boxes 200 for permitting ventilation by pulling air underneath and between adjacent boxes. The term underneath means that the corrugated material 202 extends between two boxes 200′ stacked in a vertical direction wherein air is pulled between the space formed by the corrugated material 202 over the top of a box 200′ that is positioned below the corrugated material 202 and air is also pulled between the space formed by the corrugated material 202 under the bottom of a box 200′ that is positioned vertically above the lower box 200′ and above the corrugated material 202. The corrugated material 202, 204 may be similar to egg carton separators that are used in stacking eggs in a box. In the present invention, the corrugated material 202, 204 provides an air space for permitting ventilation underneath and between the boxes 200′ to enable air to be pulled therethrough to permit thawing of a frozen commodity contained in the boxes 200′.

In the embodiment illustrated in FIGS. 9 and 10, the plurality of boxes 200′ do not include ventilation holes. The boxes 200′ are constructed of cardboard or other material and the boxes 200′ are stacked on each other. The corrugated material 202, 204 that is disposed underneath and between adjacent boxes permits ventilation by enabling air to be pulled underneath and between adjacent boxes.

It is also contemplated by the present invention to permit the corrugated material 202, 204 to be used together with the boxes that do contain ventilation holes as illustrated in FIGS. 1, 3 and 7. In this embodiment, air would be pulled through the ventilation holes in the boxes. In addition, due to the positioning of the corrugated material 202, 204 underneath and between the boxes, air would also be pulled underneath and between adjacent boxes to permit thawing of a frozen commodity contained in the boxes 200.

The configuration of the present invention affords an opportunity to utilize aisle ways in a cooler or to utilize an individual room in a cooler to thaw a commodity.

In the embodiment illustrated in FIG. 11 the plurality of boxes 300 do not include ventilation holes. The boxes 300 are constructed of cardboard or other material and the boxes 300 are stacked on each other and positioned on a pallet 310. Plastic formed spacers 302 are disposed underneath adjacent boxes for permitting ventilation by enabling air to be pulled underneath adjacent boxes.

It is also contemplated by the present invention to permit the plastic formed spacers 302 to be used together with the boxes that do contain ventilation holes H as illustrated in FIGS. 1, 3 and 7. In this embodiment, air would be pulled through the ventilation holes H in the boxes. In addition, due to the positioning of the plastic formed spacers 302 underneath the boxes, air would also be pulled underneath adjacent boxes 300 positioned above the plastic formed spacers 302 and above the boxes 300 positioned below the plastic formed spacers 302 to permit thawing of a frozen commodity contained in the boxes 300.

In the embodiment illustrated in FIG. 12 the plurality of boxes 400 do not include ventilation holes. The boxes 400 are constructed of cardboard or other material and the boxes 400 are stacked on each other and positioned on a pallet 410. Wood slat spacers 402 are disposed underneath adjacent boxes for permitting ventilation by enabling air to be pulled underneath adjacent boxes 400 positioned above the wood slat spacers 402 and above the boxes 400 positioned below the wood slat spacers 402.

It is also contemplated by the present invention to permit the wood slat spacers 402 to be used together with the boxes that do contain ventilation holes H as illustrated in FIGS. 1, 3 and 7. In this embodiment, air would be pulled through the ventilation holes H in the boxes. In addition, due to the positioning of the wood slat spacers 402 underneath the boxes, air would also be pulled underneath adjacent boxes to permit thawing of a frozen commodity contained in the boxes 400.

As illustrated in FIGS. 13 and 14 a second embodiment of the present invention is set forth wherein a plurality of pallets 601A-610A and 601B-610B of a commodity are spaced relative to each other with air handlers 600, 602 being directly disposed to be in communication with the plenum P.

As illustrated in FIGS. 13 and 14, an apparatus 500 is provided for thawing a commodity, such as thawing a food product. The plurality of pallets 601A-610A and 601B-610B are provided with the commodity stacked on the pallets and the pallets arranged in two rows with a space S formed therebetween. The term space means that the pallets are substantially equally disposed relative to each other to form a continuous space between the pallets. In addition, the term space means that the pallets may be arranged at an angle with corners of the end pallets engaging each other and the space continuing to enlarge from the end pallets to each of the air handlers 600, 602.

A cover C is positioned to be placed on the space S or at least on a portion of the top surface of the commodities for sealing the two rows of pallets along the top surface. In one embodiment, the cover C can also extend along end surfaces for sealing the space S between the two rows of pallets and the end surfaces. The cover C may be a flexible tarp for positioning on the space S or on at least a portion of the top surface of the commodities that is sucked up tight to make a seal as air is pulled through the space S formed between the pallets and through the ventilation holes H in the boxes stacked on the pallets. In another embodiment, the cover C may be a more rigid board material that is positioned on the space S or on the top surface of the commodities.

As stated above, it is to be understood that the two rows of pallets 601A-610A and 601B-610B may be arranged in straight rows as illustrated in FIG. 13. In another embodiment, the two rows I and II may be formed at an angle wherein the end pallets of boxes 601A, 601B and 610A, 610B touch each other for closing the rows. This embodiment is contemplated by the claims and is equivalent to positioning the cover C over the ends of the two rows of pallets for sealing the ends.

A plenum P is formed between the two rows of the pallets 601A-610A and 601B-610B with the plurality of pallets being spaced apart 601A-610A and 601B-610B from adjacent pallets to permit a flow of air therebetween. The boxes of commodities positioned on the pallets include a plurality of ventilation holes for permitting air to be pulled through the ventilation holes and along the length of the space formed between the pallets as the commodity is thawed.

The air handlers 600, 602 are positioned on top of and between the two rows of pallets to be in communication with the plenum P. The air handlers 600, 602 may be spaced along a length of the plenum P according to the needs of a particular thawing operation. As illustrated in FIGS. 13 and 14, the air handlers 600, 602 are disposed at approximately the one-third point along the two rows to ensure a proper flow of air between the pallets. The air handlers 600, 602 include motors 632, 634, respectively, operatively connected to fans for pulling air from between the plurality of pallets 601A-610A and 601B-610B and along a length of the space S formed between the two rows and for discharging the air either upwardly, horizontally or downwardly therefrom. The discharge of air upwardly permits the air that has been cooled by thawing a commodity to be discharged towards the ceiling in the room in which the pallets are positioned.

In another embodiment of the present invention, at least one air handler is provided for forcing air within a predetermined temperature range through the air handler and along a length of the space formed between the two rows and through the ventilation holes in the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Thus, an even flow of air is forced through the air handler, along the two rows of boxes and through the ventilation holes in the boxes to evenly thaw a commodity positioned in the boxes.

In another embodiment of the present invention, at least one air handler is provided for forcing air within a predetermined temperature range through the air handler, along a length of the space formed between the first and second boxes and through the boxes discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Thus, an even flow of air is evenly forced through the air handler, along the length of the space formed between the first and second boxes and through the first box and the second box to evenly thaw a commodity positioned in the boxes.

In a further embodiment of the present invention, at least one air handler forces air within a predetermined temperature range through the air handler, along a length of the space formed between the two rows through the ventilation spacers disposed underneath the boxes discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Thus, an even flow of air is evenly forced through the air handler, along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly thaw a commodity positioned in the boxes on the pallets.

In a further method of the present invention, air within a predetermined temperature range is forced along a length of the space formed between the two rows, through the ventilation holes in the boxes and discharged therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Thus, an even flow of air is provided to evenly force air along the length of the space formed between the two rows of boxes and through the ventilation holes in the boxes to evenly thaw a commodity positioned in the boxes.

In another method of the present invention, air within a predetermined temperature range is forced along a length of the space formed between the first and second boxes and through the boxes and discharged therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Thus, an even flow of air is provided to evenly force air through length of the space formed between the first and second boxes and through the first box and the second box to evenly thaw a commodity positioned in the boxes.

In another method according to the present invention, air within a predetermined temperature range is forced along a length of the space formed between the two rows, through the ventilation spacers and discharged therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time. Thus, an even flow of air is provided to evenly force air along the length of the space formed between two rows of pallets and through the ventilation spacers to evenly thaw a commodity positioned in the boxes on the pallets.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. 

1. An apparatus to thaw a commodity comprising: a plurality of boxes of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; a plenum formed between said two rows of boxes to permit a flow of air through ventilation holes in the boxes; and at least one air handler pulling air within a predetermined temperature range through the ventilation holes in the boxes and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; wherein an even flow of air is pulled through the ventilation holes in the boxes and along the length of the space formed between the two rows of boxes to evenly thaw a commodity positioned in the boxes.
 2. The apparatus according to claim 1, wherein said commodity is a food product.
 3. The apparatus according to claim 1, wherein the commodity is a food product and the apparatus is positioned in a cooler that is maintained at a temperature range of 37 degrees F. to 70 degrees F. (2.77 degrees C. to 21.11 degrees C.).
 4. The apparatus according to claim 1, wherein the at least one air handler is positioned approximately midway between the two rows of boxes to evenly pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 5. The apparatus according to claim 1, wherein said at least one air handler including a housing in communication with the plenum between the two rows of boxes of the commodity said at least one air handler being disposed within the housing to pull air through the ventilation holes in the plurality of boxes and along the length of the space formed between the two rows.
 6. The apparatus according to claim 5, wherein the at least one air handler includes at least one fan operatively connected to a motor being disposed within the housing to evenly pull air through the ventilation holes in the plurality of boxes and along the length of the space formed between the two rows.
 7. The apparatus according to claim 1, and further including a sealing cover on top of the space for sealing the space between the two rows of boxes to form the plenum, wherein the boxes are at least one box in width along the predetermined length or height.
 8. The apparatus according to claim 1, and further including a cover for covering any space formed between adjacent boxes and being positioned on an exterior surface of the boxes.
 9. The apparatus according to claim 1, and further including a cover for covering any space formed between adjacent boxes and being positioned on an interior surface of the boxes.
 10. The apparatus according to claim 1, and further including two or more air handlers, each air handler being mounted above and in direct communication with the plenum, each air handler being positioned between the rows of boxes and at least one fan is operatively connected to a motor disposed within each of the two or more air handlers to pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 11. The apparatus according to claim 7, wherein the sealing cover extends along end surfaces of the two rows of boxes to seal the end surface of the space between the two rows of boxes to form the plenum.
 12. The apparatus according to claim 1, wherein the at least one air handler is positioned above the two rows of boxes and being in communication with the plenum formed therebetween to evenly pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 13. The apparatus according to claim 1, wherein two air handlers are mounted above the two rows of boxes and being in direct communication with the plenum formed therebetween to evenly pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows, said two air handlers being spaced a predetermined distance from each other.
 14. An apparatus to thaw a commodity comprising: a first box of a commodity; a second box of a commodity; said first and second boxes being disposed adjacent to each other with a space formed therebetween; a plenum between said first box and said second box to permit a flow of air through the boxes; and at least one air handler pulling air within a predetermined temperature range through the boxes and along a length of the space formed between the first and second boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; wherein an even flow of air is evenly pulled through the first box and the second box and along the length of the space formed between the first box and the second box to evenly thaw a commodity positioned in the boxes.
 15. An apparatus to thaw a commodity comprising: a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; ventilation spacers positioned underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween; a plenum between said two rows of pallets wherein a flow of air is pulled through the ventilation spacers disposed between the boxes on the pallets; and at least one air handler pulling air within a predetermined temperature range through the boxes and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; wherein an even flow of air is evenly pull air through the ventilation spacers and along the length of the space formed between the two rows of pallets to evenly thaw a commodity positioned in the boxes on the pallets.
 16. A method to thaw a commodity comprising the following steps: positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween; forming a plenum between said two rows of boxes to permit a flow of air through ventilation holes in the boxes; pulling air within a predetermined temperature range through the ventilation holes in the boxes and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; and providing an even flow of air to evenly pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows of boxes to evenly thaw a commodity positioned in the boxes.
 17. The method according to claim 16, wherein said commodity is a food product.
 18. The method according to claim 16, wherein the commodity is a food product and the method is performed in a cooler that is maintained at a temperature in a temperature range of 37 degrees F. to 40 degrees F. (2.77 degrees C. to 4.44 degrees C.).
 19. The method according to claim 16, wherein the air is pulled from approximately midway between the two rows of boxes for evenly pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 20. The method according to claim 16, and further including the step of providing at least one air handler having a housing in communication with the plenum and at least one fan operatively connected to a motor disposed within the housing for pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 21. The method according to claim 16, and further including the step of providing a sealing cover positioned on top of the space between the two rows of boxes to form the plenum, wherein the boxes are at least one box in width along the predetermined length or height.
 22. The method according to claim 16, and further including the step of providing a cover for covering any space formed between adjacent boxes, said cover being positioned on an exterior surface of the boxes.
 23. The method according to claim 16, and further including the step of providing a cover for covering any space formed between adjacent boxes, said cover being positioned on an interior surface of the boxes.
 24. The method according to claim 16, and further including the step of providing at least one air handler mounted above and in direct communication with the plenum and at least one fan operatively connected to a motor disposed within the at least one air handler for pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 25. The method according to claim 16, and further including the step of providing two or more air handlers, each air handler being mounted above and in direct communication with the plenum, each air handler being positioned between the rows of boxes and at least one fan being operatively connected to a motor disposed within each of the two or more air handlers for pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 26. A method to thaw a commodity comprising the following steps: providing a first box of a commodity; providing a second box of a commodity; providing said first and second boxes being disposed adjacent to each other with a space formed therebetween; forming a plenum between said first box and said second box to permit a flow of air through the boxes; pulling air within a predetermined temperature range through the boxes and along a length of the space formed between the first and second boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; and providing an even flow of air to evenly pull air through the first box and the second box and along the length of the space formed between the first and second boxes to evenly thaw a commodity positioned in the boxes.
 27. A method to thaw a commodity comprising the following steps: providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween; forming a plenum between said two rows of pallets wherein a flow of air is pulled through the ventilation spacers disposed between the boxes on the pallets; pulling air within a predetermined temperature range through the ventilation spacers and along a length of the space formed between the two rows and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; and providing an even flow of air to evenly pull air through the ventilation spacers and along the length of the space formed between the two rows of pallets to evenly thaw a commodity positioned in the boxes on the pallets.
 28. An apparatus to thaw a commodity comprising: a plurality of boxes of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; a plenum formed between said two rows of boxes to permit a flow of air through ventilation holes in the boxes; and at least one air handler forcing air within a predetermined temperature range through the at least one air handler, along a length of the space formed between the two rows and through ventilation holes in the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; wherein an even flow of air is forced through the at least one air handler, along the length of the space formed between the two rows of boxes and through ventilation holes in the boxes to evenly thaw a commodity positioned in the boxes.
 29. An apparatus to thaw a commodity comprising: a first box of a commodity; a second box of a commodity; said first and second boxes being disposed adjacent to each other with a space formed therebetween; a plenum between said first box and said second box to permit a flow of air through the boxes; and at least one air handler forcing air within a predetermined temperature range through the at least one air handler, along a length of the space formed between the first and second boxes and through the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; wherein an even flow of air is evenly forced through the at least one air handler, along the length of the space formed between the first and second boxes and through the first box and the second box to evenly thaw a commodity positioned in the boxes.
 30. An apparatus to thaw a commodity comprising: a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; ventilation spacers positioned underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween; a plenum between said two rows of pallets wherein a flow of air is forced through the ventilation spacers disposed between the boxes on the pallets; and at least one air handler forcing air within a predetermined temperature range through the air handler, along a length of the space formed between the two rows and through the ventilation spacers positioned underneath at least adjacent boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; wherein an even flow of air is evenly forced air through the at least one air handler, along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly thaw a commodity positioned in the boxes on the pallets.
 31. A method to thaw a commodity comprising the following steps: positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween; forming a plenum between said two rows of boxes to permit a flow of air through ventilation holes in the boxes; forcing air within a predetermined temperature range along a length of the space formed between the two rows and through the ventilation holes in the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; and providing an even flow of air to evenly force air along the length of the space formed between the two rows of boxes and through the ventilation holes in the boxes to evenly thaw a commodity positioned in the boxes.
 32. A method to thaw a commodity comprising the following steps: providing a first box of a commodity; providing a second box of a commodity; providing said first and second boxes being disposed adjacent to each other with a space formed therebetween; forming a plenum between said first box and said second box to permit a flow of air through the boxes; forcing air within a predetermined temperature range along a length of the space formed between the first and second boxes and through the boxes and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; and providing an even flow of air to evenly force air along the length of the space formed between the first and second boxes and through the first box and the second box to evenly thaw a commodity positioned in the boxes.
 33. A method to thaw a commodity comprising the following steps: providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween; forming a plenum between said two rows of pallets wherein a flow of air is forced through the ventilation spacers disposed between the boxes on the pallets; forcing air within a predetermined temperature range along a length of the space formed between the two rows and through the ventilation spacers and discharging the air therefrom for thawing the commodity while not raising the temperature of the commodity above a mandated safe zone for longer than a predetermined time; and providing an even flow of air to evenly force air along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly thaw a commodity positioned in the boxes on the pallets. 